masonryedge.com44 MASONRY EDG E / thestorypole 2011 Vol 6 No 2 Masonry’s Added Value

Beaubien House, originally built as a residence in 1851,

is listed on the National Register of Historic Places and is home

to The American Institute of Architects (AIA) Michigan and

Detroit Chapters. Its three-story reddish-orange brick walls are

comprised of three wythes of brick supported by a fieldstone

foundation wall. Designed in the Italianate Townhouse style, Beaubien

House is one of the oldest remaining buildings in downtown Detroit.

Situated at 553 East Jefferson Avenue, a major east-west artery into

the city that runs parallel to the Detroit River, the historic building was

purchased by AIA in the 1980s, demonstrating to the architectural

community the importance of a presence in Detroit and maintaining

relevant historic architecture. Multiple renovations and restorations

have taken place over the years with the most significant renovation

completed in 1987 by the AIA. Its structure remains in good condition

with little settlement. Overall, the brick façade is still in excellent

condition, although the history of repairs has created a patchwork

of various mortar colors and types, with some brick replaced with

a pigmented concrete patching mixture.

Creating a Plan SmithGroup’s Building Technology Studio

(SmithGroup) has been an active participant in designing and implement -

ing renovations and repairs to the modest seven room Beaubien House

over the past eight years. In the fall of 2009, SmithGroup met with Rae

Dumke, then executive director of AIA Michigan/Detroit, Dan Zechmeister,

executive director of the Masonry Institute of Michigan (MIM), and Bob

Henderson, project manager with Detroit mason contractor Dixon Inc, to

evaluate repair and restoration needs. The East elevation was deteriorating

due to years of water draining onto the face from a neighboring roof.

Immediate repairs were required.Many brick faces in that location had

deteriorated, mortar joints were soft, with evidence of former incorrect

repointing work. At that time it was decided that a plan for future repairs

was required. This plan would

include a survey of the exterior

façade, recording of former

known repairs, identification of

future repairs prioritized and

organized on a timeline and

identification of a mortar mix

design and matching brick. This

would minimize investigative

work in the future and create a

uniform program for masonry

repairs. Most importantly, it

would also help AIA plan and

budget for future repairs.

PetrographicAnalysis Because there

were no written records containing details of previous repairs, SmithGroup determined

that the process of brick and mortar repairs needed to start at the beginning. The first

step was to remove mortar from the building to analyze it for composition. For buildings

from the 1850s, the mortar was most likely lime-based, but the analysis would tell for

certain. The key in removing mortar is to remove it from deep enough in the wall to

ensure samples are not of newer repointing mortar. In this case, multiple brick were

removed and samples were taken from within the barrier-type masonry wall. Both brick

and mortar were sent to the laboratory for analysis.

Imag

e cou

rtesy

of W

ikim

edia

and

Andr

ew Ja

mes

on

Beaubien House DetroitAIA Michigan & AIA Detroit headquartersThis work was made possible by the volunteer efforts and donation of services and materials, with sincere appreciation and thanks, by the following companies.

Architectural Services SMITHGROUP Detroit

Petrographic Analysis WISS, JANNEY, ELSTNER ASSOCIATESNorthbrook, IL

Mason Contractor DIXON INC Detroit

Masonry Services and Material Procurement Salvaged Brick GAVIN HISTORICAL BRICKSPlasterer's Sand MARSACK SAND AND GRAVELLime Cement NATIONAL BLOCKMasonry Cleaner DJ BARRON

Beaubien House Case Study:

PROACTIVE

APPROACH TO

MASONRY

PRESERVATION

Necessary for Extending a Building’s Life

by Meredith Steckling, AIA, CDT,

LEED Green Associate

Preparing a plan for masonry maintenance and repairwill keep Beaubien House in continuous service and willsave AIA Michigan, the owner, money over the long run.

Beaubien House_Final_ME-SP Vol6_No1 7/15/11 12:58 PM Page 44

masonryedge.com Masonry’s Added Value 2011 Vol 6 No 2 MASONRY EDG E / the storypole 45

Laboratory analysis can vary by type and, there fore, cost.

There are two tests generally performed: petrography and

chemistry (both were used for Beaubien House) For

petrography, the cost may run from $300 to $1,600. For

petrography and chemistry tests combined, the range is

approximately $800 to $3,000. The range of prices may also

be related to the expertise of the person analyzing the

results. In this case, a less expensive test may not yield the

same results as a more expensive one.

Wiss, Janney, Elstner Associates performed a petrographic

and chemical analysis of the mortar for its exact

composition (see sidebar, p 46). While waiting for the

results, SmithGroup performed an at-home mortar analysis

based upon instructions from the article Selecting Mortar

for Historic Preservation Projects1. The article stated that

lime-based or cement-based mortar composition could be

determined by dissolving a pulverized mortar sample in

muriatic acid. If the foam generated was amber in color, it

indicated a lime-based mortar. If the foam generated was

green, it was a cement-based mortar. After performing

the experiment, the foam generated appeared to be a

yellow color, indicating a lime-based mortar. Another

useful result of the experiment was that after the acid was

washed away, the aggregate remained. The aggregate

was given to the contractor who was more easily able to

match the new sand to the existing by eye, as well as

by the results of the petrographic analysis.

Beaubien House Mortar MixResults Petrographic analysis describes the

samples, analysis process and results. The most valuable

information provided to the mason matching the mortar

mix was the aggregate size, aggregate composition and

the hydrated lime-to-aggregate ratio. In this case, the

mortar mix was sanded, with a 1:2 3/4 lime to aggregate

ratio. Results also indicated that the mortar was a

hydrated lime-siliceous sand mortar. It included the ratio

of sand to lime, which was imperative for creating the new

mortar mix. It described the sand’s mineral compositions

and sizes that were used, which is helpful for duplicating

the mortar and is more specific than visually comparing the

sand to the aggregates gained from the muriatic acid test.

Historic Brick Procurement It is unknown whether the brick used in

Beaubien House was locally made. There

are buildings throughout Detroit that

appear to have been built with similar

brick, therefore there was a chance that

a match could be found from locally

salvaged brick.

At-home mortar analysis was performed by dissolving a pulverized mortar sample

in muriatic acid to determine cementitious composition.

1Sickels-Taves, Lauren B. “Selecting Mortarfor Historic Preservation Projects” Masonry Construction October 1, 1997.

Phot

o co

urtes

y of

Smith

Grou

p

Restoration Team Experience Since 1978

Don’t Tear it Down or Cover it with Insulation and StuccoStrengthen and stabilize masonry façades while adding veneer stiffness for added decades of protection and comfort.

CTP has engineered anchor performance solutions for claddings of brick and stone. A selection of corrosion resistant products are available to re-anchor brick to wood, concrete, steel, block, brick, metal stud, or tile back-ups.

SAVE THE WALL!

Contact our Technical Services Team withyour repair application needs for a cost effective and performance targeted veneer stabilizing solution.

CTP Grip-MaxMechanical Anchors for Stabilizing Stone Panel Veneers

CTP-16For Brick Additions or Replacement; and forBrick Veneer Stud Cavity Wall Construction.Veneer Anchoring System That Keeps the Air Barrier Intact and the Veneer in Place.

Shown Here With:

CTP Wall Tiea Multifunctional Triangle Wall Tie That Can be Used in Standard or Seismic Veneer Anchoring Applications

Proudly Made In the USA!

CTP Stitch-TieHelical Wall Tie System for Stabilizing

Veneers and Crack Repair

ANOTHERCTP

ORIGINAL!

CTP GRIP-MAX** Patent Pending

NEW!

Mechanical Repair Anchors for Stabilizing VeneersCTP Grip-Tie

7974 W. Orchard DriveMichigan City, Indiana46360-9390 • USA

Phone: (219) 878-1427Contact: Steve Getz, BSCEwww.ctpanchors.com

Engineered Anchoring Solutions Provider

Masonry Façade Re-Anchoring Solutions

Construction Tie Products, Inc. is committed to supplying

the highest quality masonry tie and construction systems

in North America and satisfying all stringent national codes and standards for today's

building structures. CTP, Inc. promises to be a reliable product source

along with on-time business integrity for all demanding builders.

� �� �� � �� �

Beaubien House_Final_ME-SP Vol6_No1 7/15/11 12:58 PM Page 45

masonryedge.com46 MASONRY EDG E / thestorypole 2011 Vol 6 No 2 Masonry’s Added Value

Deteriorated wall shows evidence of water damage from a neighboring roof’s runoff and of soft mortar joints, the result of improper pointing work performed in the past.

Henderson took brick samples

from the Beaubien House and

attempted to find a match at multiple local brick salvage yards to no avail.

When replacing a small number of brick within a large wall surface, it is

most desirable to obtain brick of the same era. If new brick are used, there

is a period after the brick are fired where the brick can expand as they

absorb water lost during the firing process. This growth can be

accommodated by weathering the brick prior to installation, but it is not as

desirable as if salvaged brick can be found. Creating new brick to match

existing may also be cost prohibitive with a small repair; salvaged brick is

more economical.

A match was eventually obtained in Iowa with brick salvaged from First

State Bank in Lineville. The bank was demolished, Gavin Historical Bricks

stockpiled the brick for resale. Beaubien House repairs required fewer than

250 brick, but due to the nature of salvaged brick, the order was increased

to 1,000. An additional 500 brick were donated by Gavin Historical Bricks.

Remaining brick will be stored for future need; however, once the supply

is exhausted, another search will be necessary. With salvaged brick, it is

likely that many won’t match in color or will be otherwise compromised;

therefore, hand selection for color and quality is necessary when selecting

brick for rebuilding walls.

The brick arrived on pallets with many of the units damaged due to the

demolition process while others appeared to have deteriorated due to long

exposure to weather. Brick was hand selected to be used in both the

mockups and for the replacement of damaged brick in the Beaubien House.

Mortar Design For a successful mortar match, multiple mockup

panels may be necessary to match both color and texture. This mortar

mixture was created per the petrographic analysis test results. Sand was

put through a sieve for granule size; grains larger than those found in the

mortar analysis were left in the sieve and discarded. The first mockups were

made for general consistency and color. The lime-based mortar, matched

to the existing for hardness, was much whiter than a standard cement-

based mortar. A decision to tint the mortar was made to more closely

match the existing weathered mortar. Without tinting, repairs would be

obvious for several years until natural dirt accumulated. Tooling methods

were also addressed to more closely match weathered mortar joints. A

typical concave joint would also affect the final appearance making the

repairs more apparent. The joints were finished to match existing.

With color in mind, portions of the remaining wall were brushed with

a mild masonry cleaner. New mockups were tinted to match the newly

cleaned mortar joints. The team experi mented using tan, grey and black

pigments to determine the best match. For longe vity, an integral black

inorganic pigment was selected, rather than a surface-applied tint.

Phot

o co

urtes

y of

Smith

Grou

p

Beaubien House

Petrographic Analysis of Historic Mortars

The Art and Science of the Match Historically, mortars were not prepared

to narrowly defined specifications. These mortars usually

incorpo rated locally derived materials and relied heavily on the

experience of the mason to produce a good quality mortar.

Today, compositional analyses of historic mortars are most often

performed to aid in formulating a replacement or repair mortar

that is compatible with the original mortar. Installation of an

improperly formulated replacement or repair mortar could

irreparably damage historic masonry. Compositional analyses

are performed in accordance with the standard test method,

ASTM C1324, Test Method for Examination and Analysis of Hardened

Masonry Mortar, which requires petrographic examination and

chemical methods of analysis.

Mortar analysis must begin with a thorough petrographic

examination to identify constituents of the fine aggregate and

paste/binder system, evaluate the air-void system (entrained or

non-air entrained) and estimate air content. Thin-section

microscopy is preferred because it allows for easier and more

precise identification of constituents and because the thin

section preserves the condition of the mortar and the relation -

ships between mortar constituents. Poor condition of the

mortar, especially extensive alteration, can adversely affect

chemical analysis. In some cases, chemical analyses cannot be

performed so the petrographic description of the mortar

provides an approximate analysis of its composition.

The chemical analysis portion of the test method combines wet-

chemical methods and instrumental analysis to determine the

crystalline components, soluble silica, calcium oxide, magnesium

oxide, magnesium hydroxide, insoluble residue and losses on

ignition. The total of insoluble residue, soluble components and

loss on ignition should be close to 100%. If it is, the chemist

calculates the mortar proportions in accordance with ASTM

C1324. If the total is more than 5% greater or less than 100%, the

possibility of interferences or biases should be examined. Mortar

compositional analysis relies heavily on the experience of the

petrographer and chemist to recognize materials that might

interfere with or bias the chemical analysis since the proportions

of mortar components are calculated from data obtained

by the chemical analysis methods.

Laura J Powers, Associate Principal and PetrographerSusanne Papas, Senior Associate and Chemist Wiss, Janney, Elstner AssociatesNorthbrook, IL 847.272.7400

ReferencesAnnual Book of ASTM Standards, Vol 4.05. West Conshohocken: ASTM International, 2010.

Beaubien House_Final_ME-SP Vol6_No1 7/15/11 12:58 PM Page 46

masonryedge.com Masonry’s Added Value 2011 Vol 6 No 2 MASONRY EDG E / the storypole 47

Repairs and DocumentationAfter mockups were evaluated and mortar

formula determined, repairs were made to

Beaubien House. The repair area was roughly

100 sf. The majority of the repair involved

repointing joints. Multiple brick were replaced

due to cracking. Another portion of the wall

contained obvious repointing with a mortar

mix that did not match the surroundings. Those

joints were raked and repointed with the new

mortar. Areas of repair were documented

photographically along with the method used,

brick supplied and formula for the mortar

mixture. A full architectural specification was

not written as the petrographic analysis report

was included in the documentation of the

process. This informa tion was compiled into

one document to be kept by the AIA.

As with any structure, Beaubien House must

be maintained and repaired. The brick

masonry structure continues to function and

look beautiful after more than 150 years of

use, while having had multiple owners and

uses. Brick is capable of lasting for thousands

of years with proper maintenance. There

is always the potential for a change of

occupants, so documentation of work is

important. In the future, a mason contractor

should not need to perform a petrographic

analysis or take mortar samples. Instead, they

can rely on the documentation to develop a

mockup and complete a repair. nnn

Meredith Steckling,AIA,CDT, LEED GreenAssociate, is an associatewith SmithGroup’sLearning and BuildingTechnology Studios. She is currently a Project Manager withextensive experience in the analysis anddevelopment of exterior

building envelopes including wall systems, roofing, windows and waterproofing.Steckling serves on the Board of theBuilding Enclosure Council – Greater DetroitChapter. She holds a Bachelor of Science inArchitecture from the University ofMichigan and a Master of Architecturefrom Lawrence Technological University.

meredith.steckling@smithgroup.com313.442.8185

Got building problems? We have your solutions.

SmithGroup Building Technology ServicesFor over 30 years, SmithGroup has o�ered comprehensive professional services including professional service evaluations; forensic investigations; traditional and specialized system and component design; construction quality management; HVAC and other system commissioning; maintenance evaluations; pre-purchase assessments; existing facility evaluations; mechanical, HVAC and electrical system analysis and design; peer review; and construction dispute support.

www.smithgroup.com

Beaubien House_Final_ME-SP Vol6_No1 7/15/11 12:58 PM Page 47